Door and method of manufacturing it



u fhfT fl Filed May 27. 1953 P. F. CACCIATORE DOOR AND METHOD OF MANUFACTURING IT Jul 17, 1956 United States Patent 6 DOOR AND METHOD OF MANUFACTURING IT Philip F. Cacciatore, Newton, Mass.

, Application May 27, 1953, Serial No. 357,675

3 Claims. (Cl. 20 -35) This invention relates to a door, and method of manufacturing it.

One object of my invention is to provide a door with two panels spaced apart by improved spacing means.

Another object is to provide such a door that is especially economical to manufacture, yet is equal in quality and appearance to more costly doors.

A further object is to provide a method of manufacturing a door that is simple, requires a relatively small number of parts, and can be produced with a minimum amount of labor.

The foregoing and other objects which will appear as the nature of the invention is better understood, may be accomplished by a construction, combination and arrangement of parts, and by a method, such as is disclosed by the drawings. The nature of the invention is such as to render it susceptible to various changes and modifications, and therefore, I am not to be limited to the construction disclosed by the drawings nor to the particular parts described in the specification; but am entitled to all such changes therefrom as fall within the scope of my claims.

In the drawings:

Figure 1 is a front elevational view of my door, a portion of the front panel being broken away.

Figure 2 is a side elevational view of my door.

Figure 3 is a side elevational view of a spacer supporting member with the spacers attached thereto in predetermined position.

Figure 4 is an enlarged, sectional View taken on the line 44 of Figure 1.

As illustrated, my door has the usual outer border or frame 10, which, as shown, consists of a top, bottom and two sides opposite each other. There is a front panel 12 and a back panel 14 which cover opposite sides of said frame and extend across the space between, thus providing the front and back face surfaces of the door. Said panels are commonly /8 inch thick and made of 3-ply face panels of hard wood.

Between said two panels 12 and 14 is spacing means which includes a supporting member 16 shown as a sheet of material such as fiber having a plurality of holes 18 therein. Said holes 18 are preferably in staggered rela tionship, those in every other row being in vertical alinement, while the holes in contiguous, horizontal rows are out of vertical alinement. For instance, the holes in the second horizontal row are located centrally between two holes in the next row above or below. This precision spacing provides balanced stability and strength, while using a minimum of separators 20, later described.

Extending into each said hole 18 is a said separator 20 which, as shown, is made of a hollow cylinder of a relatively light weight material that is strong, such as fiber. Said separators 20 are substantially the same diameter as said holes 18, or only a trifle smaller, so that when they enter said holes they will remain attached to said supporting member 16 by friction fit, with portions extending beyond opposite sides of the supporting member. The depth of said separators may be 1% inches, whereas the supporting sheet 16 could be inch thick, consequently a separator would project slightly more than /2 inch beyond both sides of the latter. The overall diameter of a separator 20 may be 3 inches for instance, while the material forming the outside rim could be Mr inch thick, leaving a diametrical opening between two rim portions of 2 /2 inches. These separators 20 may be slightly tapered between the opposite outside edges, so that one end is slightly smaller than a said hole 18 and the opposite end slightly larger.

Said separators are adhesively united to said panels 12 and 14, by a permanent bond, consequently they provide support and stability therefor. Said panels are adhesively united to and cover said outer border or frame 10, hence they provide a smooth exterior surface at the front and back surfaces of the door.

In practicing my method of manufacture said separators 20 are inserted into the holes in said sheet 16 so they project beyond it at opposite sides thereof and an adhesive A is applied to them on opposite outer edges thereof. The assembly is then laid on a said door panel as it lies flat, said panel having previously been attached to said outer frame 10. The outside edges at one side of said separators 20, together with the adhesive thereon, make contact with the door panel, where they remain. The supporting sheet 16 is of a surface area whereby it is spaced as at 22, when in correct position, from said outer border or frame 10 all around. The other said door panel is then placed on the other outside edges of the separators 20 and it also covers said outer border 10. This makes the assembly complete and it is preferably placed in a press and kept under pressure until the adhesive is set.

What I claim is:

1. A door comprising an outer border frame, two door panels attached to and supported by said outer frame at opposite sides thereof, a supporting sheet spaced from and between said panels and having a plurality of holes therein, and separators extending into said holes and beyond at opposite sides of said sheet and retained therein by friction fit, the outside edges at one side of said separators being in contact with and adhesively united to a said panel and the other outside edges being in contact with and adhesively united with the other said panel.

2. A door comprising an outer border frame, two door panels attached to and supported by said outer frame at opposite sides thereof, a supporting sheet spaced from and between said panels and having a plurality of holes therein, and separators extending into said holes and beyond at opposite sides of said sheet and retained therein by friction fit, the outside edges at one side of said separators being connected with a said panel and the other outside edges being connected with the other said panel, said sheet being spaced laterally from said border frame at all points thereof.

3. A method of assembling a door having an outer border frame and two panels, comprising placing separators in holes provided in a supporting sheet of lesser thickness than said separators so that said separators project beyond said sheet at opposite sides thereof, uniting said outer border frame to a first said panel, applying an adhesive to opposite outside edges of said separators while they are attached to said sheet in the aforesaid position, placing said sheet and separators on a said first panel at points spaced from the outer edges thereof with the adhesive on the outside edges of one side of said separators in contact with said panel, and then adhesively applying the other said panel to said separators and to said border frame, and allowing the adhesive to set while maintaining the aforesaid assembly.

References Cited in the file of this patent UNITED STATES PATENTS 2,479,870 Rundquist Aug. 23, 1949 2,524,663 Heijmer et al Oct. 3, 1950 2,538,330 Rosenhagen Ian. 16, 1951 

